Method of making boat hulls and the like and a starter shell kit therefor

ABSTRACT

A PLURALITY OF LONGITUDINALLY INTERCONNECTED KEEL-DEFININH FRAME MEMBERS AND A PLURALITY OF SPACED SIDE-DEFINING FRAM MEMBERS ARE SECURED TO THE INNER SIDE OF LONGITUDINALLY SPACED TRANSVERSE FRAME MEMBERSTO FORM AN OPEN FRAMEWORK DEFINING THE GENERAL SHAPE OF A BOAT HULL. THIN PRE-FORMED PANELS OF GLASS FIBER-REINFORCED SYNTHETIC PLASTIC ARE SECURED TO THE INNER SIDES OF THE KEEL-AND SIDE-DEFINING FRAME MEMBERS TO FORM A STARTER SHELL FOR THE BOAT. GLASS FIBER-REINFORCED SYNTHETIC PLASTIC THEN IS APPLIED OVER THE UNOBSTRUCTED INNER SURFACES OF THE PANELS TO COMPLETE THE BOAT HULL, AFTER WHICH THE EXTERNAL FRAME MEMBERS ARE REMOVED.

3 Sheets-Sheet 1 ALLEN D. PRATT INVENTOR.

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93 1971 D. PRATT METHOD 'OF MAKING BOAT HUILILS AND- THE LIKE 3 Sheets-Sheet 3 AND A STARTER SHELL KIT THEREFOR Filed June e,' 1969 D. PRATT INVENTOR v AGENT United States Patent Oflice Patented Feb. 9, 1971 ABSTRACT OF THE DISCLOSURE A plurality of longitudinally interconnected keel-defining frame members and a plurality of spaced side-defining frame members are secured to the inner side of longitudinally spaced transverse frame members to form an open framework defining the general shape of a boat hull. Thin pre-formed panels of glass fiber-reinforced synthetic plastic are secured to the inner sides of the keel-and side-defining frame members to form a starter shell for the boat. Glass fiber-reinforced synthetic plastic then is applied over the unobstructed inner surfaces of the panels to complete the boat hull, after which the external frame members are removed.

BACKGROUND OF THE INVENTION This invention relates to the making of boat hulls and like hollow objects, and more particularly to a novel method and starter shell kit for making relatively large boat hulls and the like.

Kits have been provided heretofore for making boat hulls and other hollow objects. However, they are characterized by consisting of heavy and bulky components of special shapes. These factors limit use of such kits to the making of small boats and like objects, not only because of the high cost of the components, but also because of the high cost of shipping such kits to distant locations. Moreover, the components of such kits are arranged for internal support with finishing coatings of synthetic plastic or other material being applied to the outer side. This procedure requires the costly services of in expert craftsman to produce the proper outer surface nish.

SUMMARY OF THE INVENTION In its basic concept the method and starter kit of this invention involves the assembly of relatively small and lightweight frame components and thin pre-formed panels of synthetic plastic to provide a starter shell having an unobstructed interior to which a final reinforcing thickness of synthetic plastic is applied to produce a completed boat hull or the like having a prefinished exterior surface.

It is by virtue of the foregoing basic concept that the primary objective of this invention is achieved, namely to overcome the disadvantages of prior methods and kits as explained hereinbefore.

The foregoing and other objects and advantages of this invention will appear from the following detailed description, taken in connection with the accompanying drawings of the preferred embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a view in side elevation of an assembled boat hull kit embodying the features of this invention.

FIG. 2 is a plan view of the assembled boat hull kit shown in FIG. 1.

FIG. 3 is a fragmentary transverse sectional view taken on the line 3-3 of FIG. 1.

FIG. 4 is a fragmentary transverse sectional view taken on the line 4-4 in FIG. 1.

FIG. 5 is a fragmentary transverse sectional view taken on the line 55 in FIG. 1.

FIG. 6 is a fragmentary longitudinal section taken on the line 66 in FIG. 1.

FIG. 7 is a fragmentary sectional view taken on the line 77 in FIG. 1.

FIG. 8 is a fragmentary sectional view taken on the line 88 of FIG. 1.

FIG. 9 is a fragmentary sectional view illustrating the manner of completing the boat hull from the starter shell.

DESCRIPTION OF THE PREFERRED EMBODIMENT The boat hull kit illustrated in the drawing includes a plurality of frame members interconnected to provide an open framework the interior of which defines the general shape of a desired type of boat hull. The type illustrated is a sail boat.

Thus, a plurality of keel-defining frame sections 10, 12, 14, 16 and 18 are arranged end-to-end and interconnected by such means as the connecting plates 20 and bolts 22 to provide an elongated keel-defining frame member.

Secured to the keel-defining frame member at longitudinally spaced intervals are a plurality of transverse frame members. There are three such transverse frame members in the embodiment illustrated.

The rear and intermediate transverse frame members are of generally Y-shape and are similar in construction. Thus, the rear frame member (FIG. 3) includes a pair of laterally spaced bottom sections 24 and 26, intermediate sections 28 and 30 and top sections 32 and 34, interconnected by the connecting plates 36 and bolts 38. The intermediate frame member (FIG. 4) includes a pair of laterally spaced bottom sections 40 and 42, intermediate sections 44 and 46 and top sections 48 and 50, interconnected by the connecting plates 52 and bolts 54.

The bottom pairs of sections are spaced apart by the keel-defining frame section 14 and secured thereto by the bolts 56. The bottom sections thereby support the keel section 14 in the forwardly inclined arrangement illustrated. A horizontal base member 58 also is secured between the bottom sections by bolts 60, and wedge members 62 of varying length are interposed between the base member 58 and keel section 14 to brace the latter.

The upper ends of the transverse frames may be secured together temporarily by transverse stringers 74 nailed or otherwise secured to the upper ends of the frame sections. The transverse frame members are supported in upright position by angular braces 76 extending from the side portions of the transverse frame sections angularly outward to the ground.

A plurality of side frame members interconnect the keel-defining frame member and transverse frame members. In the embodiment illustrated the upper side frame member sections 80, 82, 84, 86 and 80, 82', 84', 86, are arranged end to end and secured to the opposite upper ends of the keel-defining frame member and to the transverse frame members to define the upper periphery of the boat hull. The lower side frame member sections 90, 92, 94, 96 and 90, 92, 94', 96 are arranged end-t0- end and secured to the keel-defining frame member and transverse frame members a spaced distance below the top side frame sections. Both upper and lower side frame sections are secured to the lateral sides of the keel-defining frame member and to the inner sides of the transverse frame members, being received in notches 98 provided in the transverse frame members so that the inner sides of the side frame sections are flush with the inner sides of the transverse frame members. Accordingly, the inner sides of the keel-defining frame member, transverse frame members and side frame members define the general external shape of the boat hull.

The open framework thus constructed functions to support a plurality of thin panels 100 of synthetic plastic material, preferably glass fiber-reinforced polyester resin. Each panel is molded to a shape conforming to the area of the open framework which it is to enclose, the margins of the panel being arranged to overlie corresponding portions of the framework for attachment to the latter by such means as nails 102 (FIG. 7). It is an important advantage of the present invention that the molding of these panels to predetermined shapes provides the panels with prefinished external surfaces which require no further processing.

After all of the thin plastic panels have been secured to the inner sides of the open framework, the assembled kit forms the completed starter shell of the boat hull. The hull is completed by applying to the inner surfaces of the panels and over the joints therebetween a desired thickness of synthetic plastic material 104 (FIG. 9) sufficient to give the hull its required structural strength. Such synthetic plastic material may be applied by any one of several well known conventional techniques. Thus, multiple layers of polyester resin and glass fiber cloth may be applied. Alternatively, a mixture of glass fiber filaments and polyester resin may be sprayed upon the inner surface of the panels and then rolled to desired density. The foregoing and various other techniques, with various other materials, may be utilized, as desired.

Having thus completed the boat hull from the starter shell, the external framework of keel-defining sections, transverse frame sections and side frame sections are removed by dismantling said sections from the outside of the hull, after the latter has been appropriately braced against lateral tipping. As the frame sections are removed the exposed shanks of nails 102 or other attaching devices are cut off and ground down to the external surface of the prefinished thin panels. The joints between panels then may be filled with synthetic plastic material 106 preferably of the same type and color of the external surface of the thin panels, and then buffed to blend with the external surface of the panels.

The foregoing method and kit are particularly well suited for making boat hulls and other hollow objects of rather large size, since the components of the kit may be combined into a package of relatively small dimensions and light weight. For example, let it be assumed that the sail boat illustrated in the drawing is 40 feet in length and 10 feet across the beam and 10 feet high from the keel to the gunwale. Accordingly, none of the frame components or thin plastic panels 100 exceed about 10 feet in length. Such components may be packaged compactly for convenient and economical shipment to distant locations for assembly and completion of the boat hull. The plastic panels need be no thicker than about inch. The thickness 104 of reinforcing plastic material may be about one inch.

Further, by providing the thin plastic panels with a prefinished external surface, the hull may be completed rapidly and without the aid of expert personnel, since the roughly finished interior of the hull ultimately will be concealed by decking and other finishing components of the completed boat.

It will be apparent to those skilled in the art that various changes may be made in the size, shape, number, type and arrangement of parts described hereinbefore without departing from the spirit of this invention.

Having now described my invention and the manner in which it may be used, I claim:

1. A starter shell kit for boat hulls and like hollow objects, comprising:

(a) a plurality of frame members adapted to be secured together detachably to form an open framework the inner side of which defines the shape of the object, and

(b) a plurality of thin panels of synthetic plastic material adapted to be secured detachably to the inner side of the framework to form a starter shell for the object, which starter shell has an unobstructed inner surface to which a thickness of synthetic plastic material may be secured to complete the object, after which the external framework is removed.

2. The starter shell kit of claim 1 wherein the panels are provided with a prefinished external surface.

3. The starter shell kit of claim 1 for a boat hull, where- (a) the frame members include:

(1) a plurality of keel-defining frame sections,

(2) connector means for securing the keel-defining frame sections together longitudinally to form an elongated keel-defining frame member,

(3) a plurality of transverse frame sections,

(4) connector means for securing the transverse frame sections together in units to form a plurality of transverse frame members,

(5) securing means for attaching the transverse frame members to the keel-defining frame member at longitudinally spaced intervals,

(6) a plurality of side frame sections, and

(7) securing means for attaching the side frame sections to the keel-defining frame member and inner sides of the transverse frame members to form side frame members,

(8) the inner sides of the connected keel-defining,

transverse and side frame members thereby defining the external shape of the boat hull,

(b) and securing means detachably secures the thin panels to the inner sides of said frame members to complete the starter shell of the boat hull.

References Cited UNITED STATES PATENTS 11/1952 Nebesar 9--6 3/1963 Schmalz 9-6X 

